Method and system for constructing pre-fabricated building

ABSTRACT

The present invention is a method and system for constructing pre-fabricated buildings. Wall panels are provided wherein each wall panel has a plurality of vertically disposed channel-shaped metal studs equidistantly disposed between a bottom plate and top plate. A substantially rigid foam insert is between each of the channel-shaped metal studs of a wall panel to provide insulation and structural support to the wall panel. The foam inserts each have an aperture forming a conduit vertically disposed within the foam insert. An interior spline is inserted between adjacent wall panels and provides the mechanical connection to secure the wall panels together. The interior spline comprises rigid foam with a pair of steel facing adhered on opposing faces of the spline.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 60/754,110 filed Dec. 27, 2005. The disclosure of the provisional application is incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to building construction, and more specifically to a method and system for efficiently and economically constructing pre-fabricated residential and commercial buildings.

2. Description of the Prior Art

Construction costs and quality of manufacture are major problems in the building trades. Many building systems have been proposed and used by others to cut costs and improve quality. Those prior art systems usually have some form of panelized pre-fabricated wall segment design. Many of such systems are in use worldwide. The shortcomings of the prior art pre-fabricated structures include, but are not limited to, inadequacies in the connection between the pre-fabricated panels, inefficient HVAC systems, and susceptibility to failure under high wind loads.

One type of prior art building system provides complete walls segments with doors and windows. A shortcoming of this type of complete wall system is that it is cumbersome and does not possess the necessary commonality of use required for mass production. Further, often times there are problems associated with connecting these wall segments that results from variations in dimensional characteristics and leads to uneven gaps between the wall segments. Therefore, when typical connectors of the system are steel studs that fit within the panel track framework between wall segments, the web of the studs is incapable of being compressed, as would be needed if the gap spacing were too small, and similarly could not be extended automatically if the gap was oversized. Accordingly, what is needed in the art is a pre-fabricated building system that includes uniform wall segments and can be mass produced to reduce costs.

Another shortcoming of the prior art is the lack of sufficient strength of the connection between wall segments. For example, the shape of the opposing track sides of the wall segments, when in contact with each other, is rectangular. A loose fitting stud is inserted between wall segments and attached using screws. However, the stress on the screws connecting the wall segments together is not ideal in that scenario. Accordingly, what is needed in the art is a means to join pre-fabricated wall segments that improves the strength of the connection.

Still yet another shortcoming of the prior art is the materials that the wall segments comprise. Several manufactures fabricate wall panel segments with insulation, which are known in the art as structural panels. The structural insulated panels consist of wood or metal faced insulated cores bonded to each other. Metal and wood faced products are typically acceptable in commercial applications everywhere but meet with resistance in residential markets when used as walls. The preferred construction materials for walls in the residential market are cement-based products.

Cement faced insulated tip up panels are available in the market place. These types of panels have gained wide acceptance in commercial buildings. However, a short-coming of the tip up panels is that they are so heavy that heavy equipment is needed for panel erection. Thereby making them unattractive to the residential market. Accordingly, what is need in the art is a pre-fabricated building system that includes wall panels fabricated with cement that are easy to maneuver without the use of specialized equipment.

Another shortcoming of the prior art pre-fabricated building systems is that the HVAC systems are inefficient. For example, high velocity small diameter duct HVAC systems are in general use throughout the United States. Most installations with this type of system have two outlets per room and a secondary single remote location cold air return located elsewhere. Return duct openings must be sized to balance airflow with a minimal pressure drop to maintain maximum efficiency. If the return is too small, the pressure head suppresses airflow in the small diameter duct. Often times, each room does not have individual returns. Instead, the gap between the bottom of the door and the floor becomes the only means of exhaust. If the door is closed, the room becomes “stuffy”.

Further, it is not practical to provide each room with its own large return duct in addition to the two small diameter inlet ducts. This would also lead to an increase in air contaminants. For example, while the inlet ducting airflow is typically high of approximately 2000 feet per minute, the return duct velocity is typically less than approximately 50 feet per minute. The low velocity in the return air duct will cause dirt particles to settle out and collect in the duct itself in contrast to a high velocity airflow that would entrain the dirt particles as it flows through the ducting. Accordingly, what is needed in the art, is a pre-fabricated building system that incorporates a HVAC system that is highly efficient and hygienic.

Another shortcoming of the prior art and conventional building methods is the susceptibility to failure from high wind loads. For example, recent hurricanes caused major structural damage to homes from inadequate retention of roof structures to walls. Various building departments responded to this problem by mandating the use of hurricane straps. These straps comprise a length of light gauge steel, typically placed at intervals equal to stud spacing that connect the wall structure with roofs and to other floor levels. The level of protection has improved thereby but is still inadequate for winds in excess of 150 mph. Accordingly, what is needed in the art is a pre-fabricated building system that has improved strength and resistance to high wind loads.

It is, therefore, to the effective resolution of the aforementioned problems and shortcomings of the prior art that the present invention is directed.

However, in view of the prior art at the time the present invention was made, it was not obvious to those of ordinary skill in the pertinent art how the identified needs could be fulfilled.

SUMMARY OF THE INVENTION

The invention provides a system and method for constructing pre-fabricated buildings. The system includes providing a plurality of wall panels wherein each said wall panel having a plurality of vertically disposed channel-shaped metal studs equidistantly disposed between a bottom plate and top plate; said wall panel having substantially rigid foam insert disposed between said channel-shaped metal studs wherein said insert having an aperture forming a conduit vertically disposed within said foam insert; providing an interior spline adapted to be inserted between a first wall panel and adjacent second wall panel adaptable to secure said first wall panel and second wall panel together wherein said interior spline comprises rigid foam with a pair of steel facing adhered on opposing faces thereto; providing a bottom track adaptable to receive said bottom plate of said plurality of wall panels; providing a top track adaptable to receive said top plate of said plurality of wall panels; providing a ceiling panel supported by a top portion of said wall panels; and providing a roof panel secured to said ceiling panel and wall panel.

The components within the present invention's pre-fabricated wall panels are equivalent to standard open construction. Accordingly, a visual comparison of walls assembled from pre-fabricated wall panels with typical construction reveals some similarities. For example, both techniques are consistent with building codes for vertical spacing, facings, insulation, electrical, plumbing and HVAC. The major visual difference is in wall straightness, location, and squareness. This is a significant and important difference. The higher quality of the present invention's pre-fabricated wall panels is obtained by following strict quality control for incoming materials dimensional and performance specifications.

The present invention was developed to provide structural insulated wall panels that have cement-like facings, are lightweight, pre-insulated, and easily erected by specially trained labor. An important advantage of the present invention using labor with composite classification assembly skills for electric, plumbing, heating and air conditioning is that a single crew can quickly perform all trade requirements.

In the present invention, the accepted design of building walls with stud type framework is retained. However, the method of construction is changed as tasks performed on-site are instead completed in an off-site factory. A majority of currently common tasks, such as installing doors and windows, installing rough wiring, rough plumbing, placement of AC ducts, and applying wall facings, are done under strict quality control in the factory. For example, to build a four foot wall by traditional on site methods requires a carpenter, a block layer, an electrician, a plumber, HVAC tradesman, a dry wall crew and a painter. Time requirements are estimated in excess of one and one half hours to complete the work per four foot section. In contrast, the same four foot wall section can be constructed using the system and method of the present in approximately one minute. This rapid construction can be accomplished with a factory crew of ten workers. Further, it is estimated that labor costs are reduced to less than about 5% of traditional methods. This is accomplished by the factory placement of insulation, portions of rough wiring, and wall facings thereby eliminating the need for on site installation.

A typical full size wall segment of the present invention is 8 feet tall and 4 feet wide. Other panel widths of one foot, two feet, and three feet, headers, panels with pre-installed windows or doors, panels with one end framed to math roof slope and panels for special wall heights or widths are also contemplated by the present invention.

In accordance with the present invention, an interior space is defined by wall segments, ceiling panels and roof panels having steel and cement-faced surfaces. The space defined between the ceiling and roof panels (i.e., “attic space”) is used as a ductless cold air return. Each room of a building is connected to the attic space, for example, by a standard 6″×10″ register well known in the art. Thus, restrictions to air circulation caused by using air return ducts are substantially removed. Further, typically only one high velocity small diameter duct is required per room. In the preferred embodiment, air circulation is maintained continuously and all rooms are maintained at approximately the same temperature making balancing the system unnecessary and each room is served by one directly connected duct to the air handler.

The insulation of the attic space is equivalent to that used in commercial blast freezers. An interior temperature rise during the daylight hours is primarily a result of heat input from the occupants and from solar input through the windows. In the preferred embodiment, the windows are tempered double glazed argon fill E rated glass. Accordingly, the building will maintain a given inside temperature with little or no need for cooling or heating under normal conditions. The present invention incorporates approximately 10% minimum outside air. A separate controllable damper system is used in the nighttime hours to bring in up to 100% cooler outside air to lower the temperature in the home without the need for running the air conditioning equipment. Closing the damper in the daylight hours promotes keeping the house cool.

The present invention utilizes a full perimeter mechanical connection capable of withstanding winds up to 200 mph. Full perimeter attachment distributes uplift loads over a wide area. This results in easily managed stress loads. The lower levels of loads permit the use of light-weight easily formed metal components. These members also serve as seals against driving rain penetration similar to roof valley flashing.

The two major components of the present invention are quickly and easily installed. Installation uses a combination of adhesive bonding and mechanical screw connections. In the preferred embodiment of the present invention, a full perimeter installation can easily be completed at a rate of approximately 10 feet per minute.

Accordingly, an important object of the present invention is to provide a pre-fabricated building system that has improved strength and resistance to high wind loads.

Another important object of the present invention is to provide an efficient means of heating and cooling buildings.

Another important object of the present invention is to eliminate the need for large return air ducting in buildings.

An important object of the present invention is to provide an economic, efficient means of connecting cement fiber faced wall panels.

Another important object of the present invention is to provide an apparatus capable of maintaining contact fit between adjoining members of the pre-fabricated wall panels.

Another important object of the present invention is to provide internal clamping pressure on adjoining members during adhesive bonding.

Another important object of the present invention is to provide an efficient, economic means of producing and installing a lightweight full perimeter hurricane strap for use with construction of all type of buildings using lightweight cement fiber faces wall panels and steel faced structural insulated floor and roof panels.

Another important object of the present invention is to provide an apparatus capable of maintaining dimensional quality control of the pre-fabricated hurricane strap components.

Yet another important object of the present invention is to reduce the number of high velocity small diameter ducts to increase efficiency of the HVAC system.

Still another important object of the present invention is to replace most of the current HVAC design requirements that can only be met by skilled technicians with new HVAC designs that can be satisfied by general labor.

These and other important objects, advantages, and features of the invention will become clear as this description proceeds.

The present invention, accordingly, comprises the features of construction, combination of elements, and arrangement of parts that will be exemplified in the description set forth hereinafter and the scope of the invention will be indicated in the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

For a fuller understanding of the nature and objects of the invention, reference should be made to the following detailed description, taken in connection with the accompanying drawings, in which:

FIG. 1 is an elevational view of wall panel and its connections in accordance with the present invention;

FIG. 2 is a plan view of a corner spline and wall panel connections in accordance with the present invention;

FIG. 3 is an exploded view of a corner spline assembly in accordance with the present invention;

FIG. 4 is an exploded view of an interior spline and wall panels in accordance with the present invention;

FIG. 5 is plan view of wall panels showing interior conduits in accordance with the present invention;

FIG. 6 is an exploded view of bottom track and wall pane in accordance with the present invention;

FIG. 7 is an elevational view wall panel attached to bottom track in accordance with the present invention;

FIG. 8 is an elevational view of a wall panel insert in accordance with the present invention;

FIG. 9 is an elevational view showing the connection between a roof panel and wall panel in accordance with the present invention;

FIG. 10 is an elevational view of adjacent wall panels connected without an interior spline;

FIG. 11 is a diagrammatical view of a prior art HVAC; and

FIG. 12 is a diagrammatical view of a HVAC in accordance with the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

In the present invention, the accepted method of building walls with stud type framework is retained. However, factory assembly apparatus and process control methods capable of maintaining dimensional quality control of pre-fabricated wall segments or panels have replaced on-site framing by carpenters.

Referring now to FIG. 1, pre-fabricated wall panels 10 comprise a top plate 25 and bottom plate 15 including opposing end studs 30 to form the frame of wall panel 10. Intermediate studs 20 are interposed between ends studs 30. Foam inserts 50 are disposed within wall panel 10 and are adaptable to fit between the studs of wall panel 10. Foam inserts 50 provide support of wall panel 10 against inwardly directed force, insulation against heat transfer, vertical added load support, racking strength support, and integral chases for electrical wiring, plumbing piping and drains, HVAC duct placement, and specially system installations such as security, sound and computer. Screws 40 and bracket 35 is used to secure end studs 30 to bottom plate 15 and top plate 25. Similarly, screws 40 and bracket 35 are used to secure intermediate studs 20 to bottom plate 15 and top plate 25. End studs 30 and intermediate suds 20 are substantially perpendicular to bottom plate 15 and top plate 25.

FIG. 2 shows a plan view of two wall panels 10 being connected together at a corner using a corner spline 60. Wall board 55 is shown installed on wall panel 10. In the preferred embodiment, wall board 55 is a 7/16 inch fire rated reinforced cement panel and is adhesively bonded to wall panel 10. The purpose for this technique is to eliminate the time consuming and costly use of fasteners. It is estimated that wall board 55 can resist a soft body single penetration impact of 90 ft/lbs (ASTM E 695). Further, hard body impact resistance (ISO 7892) is estimated at 22 ft/lbs with 0.022 inch indentation and the estimated single impact penetration resistance (ASTM D 5420 method GC) is 72 in/lbs with 0.10 inch indentation or less. Tensile strength along the wall board 55 is 725 psi. Accordingly, the combined strength of wall board 55 installed on opposing faces is estimated to resist 1208 lbs/ft uplift. Shear strength of wall panel 10 is established at 50% of minimum tensile.

End stud 30 of a first wall panel 10 is adaptable to receive one end of corner spline 60. An end stud 30 of a second wall panel is adaptable to receive a second end of corner spline 60. In the preferred embodiment wall panel 10 is secured to corner spline 60 using construction adhesive. Screws 40 or other fastener means known in the art are used in alternative embodiments to secure wall panel 10 to corner spline 60.

As shown in FIG. 3, corner spline 60 comprises a substantially rigid shape adaptable to be received by end stud 30. In the preferred embodiment, corner spline 60 is polystyrene. An outer corner assembly 65 includes bracket 70 and wall board 69 adaptable to overlay bracket 70. Bracket 70 is adhesively bonded to the outer faces of corner spline. An outside corner bracket is secured over wall board 69 so that additional structural strength is provided to corner assembly 65. An interior bracket 72 provides additional support to corner spline 60. p Referring now to FIG. 4 shows interior spline 140 used to join wall panels in the same plane. In the preferred embodiment, interior spline 140 is polystyrene. End stud 30 of a first wall panel 10 is adaptable to receive a first end of interior spline 140 and end stud 30 of a second wall panel 10 is adaptable to receive a second end of interior spline 140. In the preferred embodiment, a pair of steel facings 145 are secured to opposing sides of interior spline 140 using construction adhesive. Steel facings 145 allow screws 40 to penetrate and secure interior spline 140 to end studs 30 of adjacent wall panels 10. The edges of steel facing 145 are slightly chamfered by bending, or machining a chamfer on an edge. Chamfering is advantageous during assembly of wall panels by preventing edge-to edge lock. As spline 140 enters the opening formed between two adjacent panels 10, the polystyrene material is slightly compressed resulting in an outward pressure on steel facings 145 maintaining contact fit with wall panel 10 frame elements.

FIG. 5 is a plan view showing wall panels 10 having a conduit 90 disposed through the center of each foam insert 50. Conduits 90 provide for electrical connections, plumbing, or a variety of other needs to easily be made on the vertical surface of wall panel 10. A penetration (not shown) is made through wall board 55 to access conduit 90. Wire or plumbing is inserted through conduit 90 at a top portion of wall panel 10. FIG. 5 also shows a typical wall panel assembly of the present invention consisting of both corner spline 60 and interior spline 140.

FIG. 6 shows bottom track 75 secured to floor substrate, which is a slab or other type of foundation, using an anchor 85. In the preferred embodiment, bottom track 75 is provided having a 3 5/8″ base and 1 1/4″ flanges made of a 20-ga 33 ksi steel. Track foam 80 is used to fill in the void formed between bottom plate 15 of wall panel 10 when secured over bottom track 75. Once wall panel 10 is placed over bottom track 75, screws 40 are used to firmly secure wall panel 10 to bottom track 75. Wall board 55 is shown in FIG. 6 attached to wall panel 10. Bracket 79 is disposed at intersection between vertical plane of wall panel 10 and horizontal plane of floor substrate and over wall board 55. In the preferred embodiment, a base board is used to conceal bracket 79 and for aesthetics. FIG. 7 shows the wall to floor assembly. Sequence of assembly is important. The first assembly step requires, that, depending on the scenario, a first end of corner spline 60 or interior spline 140 is attached to end stud 30 of a first wall panel.

Referring now to FIG. 8 shows an elevational view of insert 50, which is typically rectangular in shape. Insert 50 is rigid foam in the preferred embodiment and includes a preformed conduit 90 substantially in the center from top to bottom.

FIG. 9 shows a wall to roof connection including a hurricane strap 125. A ceiling panel 110 is shown attached to wall panel 10. Ceiling panel 110 is supported by wall panel 10. Similar to bottom track 75 shown in FIG. 7, a top track 95 is used to secure wall panel 10. A roof panel 120 intersects ceiling panel 110 at a pre-determined angle. Hurricane strap 125 is connected to an outer portion of wall panel 10, to the underside of roof panel 10, and to a top portion of ceiling panel 110 using screws 40. Hurricane strap 125 may be formed of either a single brake metal piece or two separate brake metal pieces and matches the roof pitch. A decorative rib 130 is disposed on roof panel 120 for aesthetics. The accepted code requirement to connect building walls and roof components is retained. However, on site placement by carpenters of point spaced metal straps has been replaced by factory produced perimeter hurricane strap 125 capable of retaining connection integrity estimated at winds of up to 200 mph.

Referring now to FIG. 10 shows framing components of wall panel 10. It is desirable for the wall panel to provide a cavity 135 for large mechanical devices or appurtenances. This is accomplished with the present invention by eliminating interior spline 140 and using only the pair of steel facings 145 to join adjacent wall panels 10. Cavity 135 is formed between vertically disposed end studs 30 and top plates 25 of adjacent wall panels 10.

FIG. 11 is a prior art HVAC system with a blower/coil module 150 interposed between return vent 160 and plenum kit 165. Air handler 170 distributes conditioned air through small diameter distribution ducts 175. Only one return vent 160 and return air duct 155 is shown as an example to illustrate one return vent is associated with a number of distribution ducts. Airflow input to the blower/coil module 150 is through the inside of return air duct 155. Air is cooled in blower/coil module 150 by about 25 to 28 degrees Fahrenheit, with a discharge temperature of about 42 degrees Fahrenheit. Moisture condenses onto the cold surface where it collects, drips off the coil and into a condensate drain (not shown). The length of return air duct 155 is exposed to surrounding attic temperatures into the home and will be substantially elevated in the summer and cool in the winter depending on the climate. Air handler 170 receives cooled or heated air from insulated plenum kits 165. Plenum 165 is insulated to R6 to mitigate temperature differentials within it as a result of attic temperatures. Distribution ducts 175 transfer conditioned air to desired rooms of a home. Single centrally located return vent 160 will draw a higher volume of air from the closest of distribution ducts 175. As a result, rooms having the greatest distance from return vent 160 require two or more distribution ducts to balance the system. Further, any obstruction to return vent 160, such as a closed door, has a substantial negative effect on efficiency.

In the preferred embodiment and as shown in FIG. 12, there are no return air ducts. Return air vent 160 is in communication with blower/coil module 150 using attic space above ceiling panels. Accordingly, attic space is a climate controlled environment. Attic space becomes a source of inlet air to blower/coil module 150. All inlet air within this space is at the same temperature as the living spaces. In the advanced technology system of the invention, air is under constant circulation. The entire structure is insulated similar to that of a blast freezer. The major input of heat is only as a result of human occupant's body temperature and minimal transfer of heat through double glazed, high E glass. If the temperature does rise sufficiently to call for conditioning, the system needs to operate for a very short period of time. To prevent a too short cycle frequency, blower/coil module 150 is sized to approximately 20% of a system to be used in other methods of construction. Distribution ducts 175 have equal backpressure for return air. This is as a result of placing 6″×10″ register 160 in each room that opens into attic space. In the present invention, one distribution duct 175 and one return vent 160 is required in each room to provide proper indoor air quality. A damper/diverter system is used with the present invention to mix outside fresh air with the re-circulated conditioned inside air.

It should be understood that although the preferred method of assembling pre-fabricated building wall panels and the methods of application use unique methods, other process and apparatus might be employed. Further it is understood that the apparatus may be altered to accommodate a variety of building sizes and shapes.

Readily understandable diagrams of the present invention described herein illustrate the configurations of the method and system for constructing pre-fabricated buildings. The diagrams show those specific details that are pertinent to the present invention so as not to obscure the disclosure with details, which will be readily apparent to those skilled in the art of having the benefit of the description herein. Thus, the diagrams shown in the drawings are primarily intended to show the various components of the invention in convenient functional groupings, so that the present invention may be more readily understood.

Accordingly, the particular embodiments disclosed above are illustrative only, as the invention may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown. It is therefore evident that the particular embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the invention.

It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention, which as a matter of language, might be said to fall there between.

Now that the invention has been described, 

1. A method for constructing pre-fabricated buildings, the method comprising: providing a plurality of wall panels wherein each said wall panel having a plurality of vertically disposed channel-shaped metal studs equidistantly disposed between a bottom plate and top plate; said wall panel having substantially rigid foam insert disposed between each said channel-shaped metal studs wherein said insert having an aperture forming a conduit vertically disposed within said foam insert; providing an interior spline adapted to be inserted between a first wall panel and adjacent second wall panel and adaptable to secure said first wall panel and second wall panel together wherein said interior spline comprising rigid foam having a pair of steel facings adhered on opposing faces thereto so that when said wall panels are secured together with said interior spline an enclosure is formed; providing a bottom track adaptable to receive said bottom plate of said plurality of wall panels; providing a top track adaptable to receive said top plate of said plurality of wall panels; providing a ceiling panel supported by a top portion of said wall panels; and providing a roof panel secured to said ceiling panel and wall panel.
 2. The method of claim 1 further comprising providing a corner spline adapted to be inserted between a first wall panel and a substantially perpendicular second wall panel adaptable to secure said first wall panel and substantially perpendicular second wall panel together wherein said corner spline comprises rigid foam having a pair of steel corner facings adhered thereto.
 3. The plurality of wall panels of claim 1 further having wall board secured on opposing faces.
 4. The method of claim 2 further comprising providing an outer corner assembly having a bracket and wall board adaptable to secure over said corner spline so that a smooth transition is realized between said perpendicular wall panels.
 5. The method of claim 4 further comprising providing an interior bracket adaptable to secure to an inside face of said corner spline.
 6. The interior spline of claim 1 further comprising polystyrene.
 7. The steel facings of claim 1 further comprising chamfered edges so that easy assembly of said plurality of wall panels is promoted.
 8. The method of claim 1 further comprising providing a strip of foam adaptable to fit within said bottom track.
 9. The method of claim 1 further comprising providing a brake metal hurricane strap adaptable to secure to a top portion of said ceiling panel, to an underside portion of said roof panel and to an exterior surface of said wall panel so that a continuous path is formed.
 10. The method of claim 1 further comprising providing an attic space of said pre-fabricated building formed between said roof panels and ceiling panels wherein said attic space is in communication with living space of said prefabricated building and an HVAC system so that said attic space is climate controlled and improves efficacy of said HVAC system.
 11. A system for constructing pre-fabricated buildings, the system comprising: a plurality of wall panels wherein each said wall panel having a plurality of vertically disposed channel-shaped metal studs equidistantly disposed between a bottom plate and top plate; said wall panel having substantially rigid foam insert disposed between each said channel-shaped metal studs wherein said insert having a aperture forming a conduit vertically disposed within said foam insert; an interior spline adapted to be inserted between a first wall panel and adjacent second wall panel and adaptable to secure said first wall panel and second wall panel together wherein said interior spline comprising rigid foam having a pair of steel facings adhered on opposing faces thereto so that when said wall panels are secured together with said interior spline an enclosure is form; a bottom track adaptable to receive said bottom plate of said plurality of wall panels; a top track adaptable to receive top plate of said plurality of wall panels; a ceiling panel supported by a top portion of said wall panels; and a roof panel secured to said ceiling panel and wall panel.
 12. The system of claim 11 further comprising a corner spline adapted to be inserted between a first wall panel and a substantially perpendicular second wall panel adaptable to secure said first wall panel and substantially perpendicular second wall panel together wherein said corner spline comprises rigid foam having a pair of steel corner facings adhered thereto.
 13. The plurality of wall panels of claim 11 further having wall board secured on opposing faces.
 14. The system of claim 12 further comprising an outer corner assembly having a bracket and wall board adaptable to secure over said corner spline so that a smooth transition is realized between said perpendicular wall panels.
 15. The system of claim 14 further comprising an interior bracket adaptable to secure to an inside face of said corner spline.
 16. The steel facings of claim 11 further comprising chamfered edges so that easy assembly of said plurality of wall panels is promoted.
 17. The system of claim 11 further comprising a strip of foam adaptable to fit within said bottom track.
 18. The system of claim 11 further comprising a brake metal hurricane strap adaptable to secure to a top portion of said ceiling panel, to an underside portion of said roof panel and to an exterior surface of said wall panel so that a continuous path is formed.
 19. The system of claim 11 further comprising an attic space of said pre-fabricated building formed between said roof panels and ceiling panels wherein said attic space is in communication with living space of said prefabricated building and an HVAC system so that said attic space is climate controlled and improves efficacy of said HVAC system.
 20. The system of claim 19 further comprising a damper system in communication with said HVAC system and ambient air so that fresh air is mixed with said re-circulated conditioned air of said living space. 